ROTARY VANE AIR COMPRESSORS: THE FUTURE IS NOW Why are rotary vane compressors the leading solution for today s automotive service industry?
In the automotive service industry, compressed air is an absolute necessity. In body shops, air compressors are utilized almost constantly for spray painting, grinding, welding and cleaning surfaces while automotive repair facilities require air to power a variety of tools, as well as impact guns and tire machines. For an industry that relies so heavily on compressed air, a faulty compressor is a serious issue. An inefficient or unreliable air supply impedes employees work, and fixing the problem often requires the company to incur time-consuming and pricey maintenance services. Furthermore, a poorly operating compressor can easily send energy bills through the roof. Today, an increasing number of automotive body and repair shops have found a solution to these issues in rotary vane air compressors. Although piston compressors were the most common system in the past, rotary vane air compressors have made significant gains within this particular industry. In this ebook, we will review the differences between piston and vanes and why rotary vane systems are today s leading solution for the automotive sector. The Old Guard: Piston-Powered Compressors In the past, the more traditional way of supplying air throughout auto repair and body shops was with piston compressors. Because these machines are typically less expensive to purchase up-front than other compressors, they became the industry standard. Waiting for an air compressor to kick-in was an understood practice, as pistons units had to work up to a pressure, shut off, then build that pressure back up again once the pressure in the tanks went down. However, as manufacturers sought to lower costs, they made the size of the pistons pumps smaller and less robust. While manufacturers may have assumed these changes would have little impact on the machine, in reality, they significantly altered the product. We ve seen the quality of piston compressors really decrease, said Ennis Mobley, President of Automotive & Industrial (A&I) Sales Associates, Inc. Located in Powder Springs, Georgia, A&I Sales specializes in assisting the automotive service industry with the selection, placement, and proper operation of air compressors. Having worked with all types of compressors for nearly 30 years at A&I, Mobley has experienced firsthand the change in pistons. Today s pistons have pumps running at a much higher speed, and these compressors are not designed to run as hard or as fast as how they re being used, he explained. Because of this, we re commonly seeing the valves and pumps fail much earlier. The crankshafts are also breaking because the pumps are so overworked. Mobley said that the noise is another drawback to pistons: We can install a rotary vane compressor in an automotive shop or parts room where employees are working but we can t do this with a piston compressor. They re just too loud.
The New Trend: Rotary Vane Compressors Rotary vane compressors are coveted by leading automotive facilities for the durability, reliability and energy efficiency that these quiet workhorses can successfully deliver. A vane offers the competitive edge companies need in order to enhance workplace productivity and quality, improve profitability and maximize operational efficiencies. Not only can vanes operate intermittently to meet the needs of auto repair shops, they can run flat-out, non-stop to readily meet the demands of high output collision repair shops. Designed for the 24-hour demands of industrial facilities, today s leading automotive repair and body shops enjoy the benefits of a rotary vane compressor engineered to be consumers first and only compressor. The dependability of rotary vane compressors versus piston units is incomparable, said Mobley. We have one of our accounts switching all of their automotive facilities from pistons to vanes. Rotary Vane Compressors: A Legitimate Cost Savings Among Other Benefits ENERGY EFFICIENCY Consider this: Eighty-three percent of total air compressor costs are related to energy usage. In comparison, purchase price only reflects 11% of the total cost of ownership and maintenance only represents 6%. With this in mind, when choosing an air compressor, a system s energy consumption should be a primary concern. In order to get the most value for your operating budget, you want a system that delivers more air for less energy which is exactly what a rotary vane system offers. The advanced design of rotary vane compressors creates a near-perfect airtight seal in the rotor stator unit, which enhances volumetric efficiency and reduces the amount of energy required to deliver the air. This means vane compressors can achieve mechanical efficiencies of up to 90%. Breakdown of Compressor Costs Energy Consumption Puchase Price Maintenance DUTY CYCLE The duty cycle of a compressor is the maximum recommended percentage of time it cycles before shutting down to prevent overheating and component wear. One benefit of rotary vane compressors is a significantly long lifespan thanks to an extended duty cycle. In contrast, a typical piston compressor has a duty cycle of 70% in order to cool the valves and ensure a reasonable life cycle. As such, this means consumers must size a piston compressor to be as much as twice the size needed. A properly sized rotary vane compressor is often one size smaller than a piston, as it is engineered to deliver a continuous (100%) duty cycle for hours on end.
OPERATING TEMPERATURES With any industrial process, heat is wasted energy. However, advancements in rotary vane technology have translated to lower operating temperatures, thereby yielding more efficient results. In the auto repair and auto body industries, reduced operating temperatures are especially critical, as high discharge temperatures create moisture levels that can affect costly equipment, such as spray booths and pneumatic tools. Rotary compressors have an average operating temperature somewhere between 170 F to 200 F, whereas piston units can run as high as 400 F. Additionally, rotary vane compressors integrate an air-cooled aftercooler that removes 65% of the condensable moisture to deliver drier air to your system. AIR QUALITY Rotary vane compressors integrate high-efficiency filtration to ensure as little as 1-3 ppm of oil carryover enters the air system to prevent contamination of equipment or processes. Traditional piston compressors can pass 25 ppm or more, particularly if they run unloaded for periods of time. Rotary vane compressors are valued for their reliable delivery of high-quality air which keeps everything downstream running better and longer. LIFE EXPECTANCY Rotary vane compressors are designed to operate for up to 100,000 hours and it is not uncommon for the systems to exceed this timeframe. Simply put, these systems are built to last. Rotary vane systems longevity is greatly enhanced by their low operating speeds and bearingless airends. While piston compressors may be less of an initial cost, they do not possess the same durability as rotary vanes. The extensive life expectancy of rotary vane compressors means when you decide it s time to transition away from your business, you ll most likely pass your rotary vane onto the next owner. Yes, they last that long, which is a key factor when considering the total cost of ownership. Get Your Last Air Compressor First With the advent of the rotary vane technology, there is every reason for auto repair shops to replace their old school pistons with a rotary vane compressor. Automotive shops can t afford to be without air, said Mobley. They can t generate revenue without air. An air compressor is one of the most important investments for their business. A rotary vane compressor is a modest investment with invaluable ROI. Remember, for every dollar spent on compressed air, 83 cents will be used for energy costs and 6 cents will be used for maintenance costs. Purchase price is a mere 11 cents. That is why, at Mattei, we are constantly working to help auto professionals reduce their cost of operation while also keeping upfront costs competitive with piston compressors.
The BLADE: Your Ultimate Solution Mattei s BLADE Series is the ideal solution for small- to medium-sized automotive repair and body shops. The BLADE combines a simple design, dependable components, and slow operating speeds (from 1,050 to 2,332 rpm) to supply consistent air pressure and quality for any application. Low Operating Costs: The BLADE provides constant clean air while consuming up to 20% less energy than competitors compressors. Inherently Quiet: The BLADE Series is housed in a stainless steel cabinet, and with speeds as low as 1,050 rpm, it delivers sound levels as low as 61 db(a). Simple, Reliable Controls: The BLADE also contains our MAESTRO XB microprocessorbased controller with both Automatic and Continuous operating modes, to satisfy all users compressed air requirements. The Automatic mode is designed for shops with fluctuating air demands, and can start and stop the motor to match intermittent air demands. The Continuous mode allows the compressor to run constantly and consistently for applications with heavy air demands. These control modes allow the BLADE to better adapt to the demands of each unique system. Contact Matti to Learn More A rotary vane air compressor from Mattei requires little maintenance, and will likely be the last compressor you ll ever need to buy. Contact Mattei today today to learn more about our BLADE Series and our other superior compressed air solutions to ensure you get a clean, dry supply of compressed air to your shop.